Phosphonite ligands, catalyst compositions and hydroformylation process utilizing same

“Not Applicable”

“Not Applicable”

1. Field of the Invention

This invention relates to the use of certain ferrocene bisphosphonite ligands in the presence of a Group VIII metal to catalyze the hydroformylation of C 4 to C 20 conjugated dienes to alkenals. The invention also relates to composition of selected hydroformylation catalysts derived from phosphonite ligands and a Group VIII metal. The invention further relates to the composition of the phosphonite ligands.

2. Description of the Related Art

The hydroformylation of alkadienes to produce alkenals, for example the hydroformylation of butadiene to pentenals, is generally known. Pentenals are potential intermediates to a variety of useful compounds. Pentenals may be oxidized and optionally esterified to pentenoic acids or methyl pentenoates, which in turn can be hydroformylated to 5-formylvaleric acid or 5-formylvalerates. 5-Formylvaleric acid and 5-formylvalerates are useful intermediates in the production of epsilon caprolactam. Currently processes for the direct production of pentenoic acids or methyl pentenoates by carbonylation of butadiene may require high temperatures; i.e., greater than 120° C. An advantage of hydroformylation of butadiene to pentenals is that it requires much lower temperatures; i.e., less than 100° C.

Most processes to produce pentenoic acid or pentenoate esters involve the use of halide promoted catalysts such as described in U.S. Pat. Nos. 5,250,726 and 5,288,903. These processes have the disadvantage that they use high concentrations of hydrohalogenic acids and other rigorous conditions, which necessitate cost-increasing measures in connection with safety and the corrosion of the equipment. In U.S. Pat. No. 5,028,734 issued Jul. 2, 1991, a process is described for the selective carbonylation of a conjugate diene by contacting with carbon monoxide in the presence of a hydroxyl group-containing compound such as methanol. This catalyst system is less corrosive than the process that is described in U.S. Pat. Nos. 5,250,726 and 5,288,903 but still has the disadvantage of requiring the use of a catalyst consisting of palladium, a bidentate phosphine and an acid to catalyze the transformation of butadiene to pentenoate esters. The main disadvantage of the presence of an acid is its reactivity towards the alcohol and the bidentate phosphines used in the process. Alcohols will react with the acid promoter to produce esters and phosphines will be converted to phosphonium salts. The combination of these two factors renders the invention described in U.S. Pat. No. 5,028,734 non-practical from an industrial point of view.

Pentenals may be alternatively hydrogenated to pentenols, which upon hydroformylation give hydroxyhexanals. 6-Hydroxyhexanal is a useful intermediate in the production of epsilon caprolactone.

Pentenals may be alternatively hydroformylated to dialdehydes, including adipaldehyde. Adipaldehyde is a valuable intermediate which is potentially useful in the production of compounds such as adipic acid (by oxidation), hexamethylenediamine (by reductive amination), and 1,6-hexanediol (by hydrogenation). Production of adipaldehyde by hydroformylation of pentenals would be a desirable improvement over current processes based on the oxidation of cyclohexane because it is based on butadiene, a less expensive feedstock.

Although a variety of complexes of bis(phosphorus) ligands with rhodium catalyze the hydroformylation of butadiene, the selectivity for 3- and 4-pentenals is low for many of them. Various publications in the 1970's and 1980's, describe hydroformylation of butadiene catalyzed by rhodium complexes with monodentate phosphines (For example, Fell, B. and W. Rupilius Tetrahedron Lett. 1969, 2721-3; Fell, B. and W. Boll Chem .- Ztg. 1975, 99, 452-8; Fell, B., W. Boll, and J. Hagen Chem .- Ztg. 1975, 99, 485-92; Fell, B. and H. Bahrmann J. Mol. Catal. 1977, 2, 211-18). These systems yield primarily valeraldehyde because the rhodium/phosphine catalysts are also very efficient catalysts for hydrogenation. Van Leeuwen reported that under mild conditions (95° C. and 175 psi, (1.2 MPa), 1:1 H 2 /CO) rhodium complexes of bidentate phosphines also yield primarily valeraldehyde (European Patent No. EP33554 A2, Van Leeuwen, P. W. N. M. and C. F. Roobeek J Mol. Catal. 1985, 31, 345-53). Recently, however, Ohgomori reported that under more vigorous conditions (100° C. and 1300 psi, (8.9 MPa), 1:1 H 2 /CO) these catalysts give 3-and 4-pentenals (Ohgomori, Y., Suzuki, N., and Sumitani, N. J. Mol. Catal. 1998, 133, 289-291). However, under these conditions the pentenals undergo further hydroformylation to a mixture of dialdehydes, lowering the yield. It has also been reported that hydroformylation of butadiene under biphasic conditions using the sulfonated phosphine P(C 6 H 4 -3-SO 3 Na) 3 yields 3-pentenal (B. Fell, P. Hermanns, and H. Bahrmann, J. Parrot. Chem., 340 (1998), pp. 459-467, German Patent No. DE 19532394).

A recent series of patents (U.S. Pat. No. 5,312,996, U.S. Pat. No. 5,817,883, U.S. Pat. No. 5,821,389, European Patent No. 872,469, European Patent No. 872,483, U.S. Pat. Nos. 5,892,127, 5,886,237, and European Patent No.872,483) discloses a hydroformylation process in which rhodium complexes of bidentate phosphite ligands catalyze the hydroformylation of butadiene to 3-pentenals. U.S. Pat. No. 5,710,344 discloses the use of rhodium complexes of bidentate phosphorus ligands wherein the ligand contains a bridging group bonded through P—O bonds to a pair of trivalent phosphorus atoms with the other two bonds to each phosphorus being either a pair of P—N bonds (phosphorodiaminites), a pair of P—C bonds (phosphinites) or one P—N and one P—C bond (phosphoroaminites).

These prior art processes using rhodium complexes of bidentate phosphorus ligands to produce 3-pentenal from butadiene have various disadvantages. For example, the isolation of 3-pentenal in these systems is complicated by side reactions such as isomerization to 2-pentenal, reduction to valeraldehyde, and further hydroformylation to a mixture of dialdehydes. Thus, these catalysts do not give high selectivity to 3-pentenal at high conversions of butadiene. For example, the highest selectivity reported for a rhodium complex of a bis(phosphite) ligand is 84% at 37% conversion of butadiene (U.S. Pat. No. 5,886,237). The bis(phosphinite) ligands disclosed in U.S. Pat. No. 5,710,344 disclose up to 95% selectivity at 95% conversion of butadiene, but only in the presence of greater than 5 equivalents of the bis(phosphinite) ligand.

Although bidentate phosphonite ligands are not commonly used in catalysis, they have been employed as catalysts for a variety of transformations, including nickel-catalyzed cyclotrimerization of alkynes ( Heterocycles, 1997, 44, 443-457), nickel- and palladium-catalyzed alkylations and cross couplings ( J. Org. Chem. 1995. 60, 2016-2 ; J Chem. Soc., Perkin Trans. 1, 1995, 17, 2083-96), nickel-catalyzed hydrocyanation of olefins (U.S. Pat. No. 5,523,453), and rhodium-catalyzed enantioselective hydrogenation of olefins (Reetz, M., Gosberg, A., Goddard, R., Kyung, S.-H.. Chem. Commun. 1998, 19, 2077-2078).

Bidentate phosphonite ligands based on a ferrocene backbone have been disclosed in U.S. Pat. No. 5,817,850 (see Fig. A below) and Chem. Commun. 1998, 19, 2077-2078. The bidentate phosphonites described in these publications have biphenol or binaphthol derived terminal groups that are bridged. U.S. Pat. No. 5,817,850 discloses a hydrocarbonylation reaction of an alkene with carbon monoxide and hydrogen to form an aldehyde which is catalyzed by a transition metal complex of the bridged terminal group containing ferrocene bis(phosphonite) disclosed therein.

(X is alkylidene, S, Se, or a direct bond)

Furthermore, while the catalyst systems described above may represent commercially viable catalysts, it always remains desirable to provide even more effective, higher performing catalyst precursor compositions, catalytic compositions and catalytic processes to achieve full commercial potential for a desired reaction. The improvement in effectiveness and/or performance may be achieved in any or all of rapidity, selectivity, efficiency or stability.

The successful hydroformylation of conjugated dienes and/or selectivity for linear aldehyde products are particularly desirable attributes.

The invention provides for a bidentate phosphonite ligand having the structure represented by the following Formula I:

wherein the Ar groups are either the same or different unbridged organic aromatic groups such as substituted or unsubstituted phenyl, substituted or unsubstituted naphthyl, mixtures thereof or the like. It should be appreciated that for purposes of this invention the above structural formula is illustrative of the staggered configuration of phosphonite ferrocene; i.e., (η 5 -C 5 H 4 P(OAr) 2 )Fe, but is not intended to be limiting. As such the eclipsed configuration as well as rotational variations thereof are to be considered intrinsically equivalent to the illustrated staggered configuration as generally known in the art.

The present invention further provides for a hydroformylation process comprising the steps of reacting an ethylenically unsaturated compound with CO and H 2 in the presence of a catalyst composition comprising a Group VIII metal or Group VIII metal compound and phosphonite ligand having a structure represented by Formula I and thus producing an aldehyde. The invention is especially directed to a hydroformylation process involving the reaction of a conjugated C 4 to C 20 diene with CO and H 2 in the presence of the catalyst composition.

The invention also provides for certain bidentate phosphonite ligands and catalyst compositions made therefrom useful in hydroformylation processes. In particular, these include the combination of a ligand of Formula I with a suitable Group VIII metal or Group VIII metal catalyst precursor.

The FIGURE is a plot of the cumulative millimoles of 3- and 4-pentenals (PAL) produced by the hydroformylation of butadiene (BD) per gram of internal GC standard, ortho-dichlorobenzene (ODCB), as a function of time using rhodium complexed with a di(2-t-butylphenylphosphonite) ferrocene ligand (Ligand 2) according to the instant invention compared to using bis(diphenylphosphinic) butane (DPPB) as the rhodium-complexing ligand.

The catalyst compositions useful in the processes of the invention are comprised of certain bidentate phosphonite ligands and a transition metal.

The phosphonite ligands described in Formula I may be prepared by a variety of methods known in the art. 1,1′-Dilithioferrocene can be prepared according to J. Organomet. Chem., 1971, 27(2). 241-0, 1,1-Bis(dichlorophosphino)ferrocene can be prepared from 1,1,′-dilithioferrocene according to Phosphorus, Sulfur Silicon Relat. Elem., 1992, 68(1-4), 99-106 or Chem. Commun . ( Cambridge ), 1998, 19, 2077-2078. Ligands of Formula I can be prepared by contacting 1,1′-bis(dichlorophosphino)ferrocene with four or more equivalents of a substituted or unsubstituted phenol. Chem. Commun . ( Cambridge ), 1998, 19, 2077-2078 describes the related reaction of 1,1′-bis(dichlorophosphino)ferrocene with (R)-binaphthol at temperatures greater than 25° C. We have found, however, that in the presence of a base such as triethylamine, this reaction can be carried out at room temperature.

Alternatively, phosphonite ligands described in Formula I may be prepared by contacting 1,1′-dilithioferrocene with a phosphorochlorodite of Formula II.

wherein the Ar groups are unbridged and can be any substituted or unsubstituted phenyl, naphthyl, or other aromatic constituent.

Phosphorochloridites may be prepared by a variety of methods known in the art, for example, see descriptions in Polymer, 1992, 33, 161; Inorganic Synthesis, 1966, 8, 68; U.S. Pat. No. 5,210,260 ; Z. Anorg. Allg. Chem., 1986, 535,221. With ortho-substituted phenols, phosphorochloridites can be prepared in situ from PCl 3 and the phenol. Also, phosphorochloridites of 1-naphthols can be prepared in situ from PCl 3 and 1-naphthols in the presence of a base like triethylamine. Another process for preparing the phosphorochlorodite comprises treatment of N,N-dialkyl diarylphosphoramidite with HCl. ClP(OMe) 2 has been prepared in this manner, see Z. Naturforsch, 1972, 27B, 1429. Phosphorochloridites derived from substituted phenols have been prepared using this procedure as described in commonly assigned U.S. Pat. No. 5,821,378.

By contacting the thus obtained (OAr) 2 PCl with 1,1′-dilithioferrocene, for example by the method described in U.S. Pat. No. 5,817,850, a bidentate phosphonite ligand according to the invention is obtained which also can be used in the process according to the invention.

The transition metal of hydroformylation catalyst system may be any transition metal capable of carrying out catalytic reaction and may additionally contain labile ligands, which are either displaced during the catalytic reaction or take an active part in the catalytic transformation. Any of the transition metals may be considered in this regard. The preferred metals are those comprising Group VIII of the Periodic Table. The preferred metals for hydroformylation are rhodium, cobalt, iridium, ruthenium, palladium and platinum, and rhodium is especially preferred.

Group VIII compounds suitable for hydroformylation, can be prepared or generated according to techniques well known in the art, as described, for example, WO 95 30680, U.S. Pat. No. 3,907,847, and J. Amer. Chem. Soc., 1993, 115, 2066. Examples of suitable Group VIII metals are ruthenium, rhodium, and iridium. Suitable Group VIII metal compounds are hydrides, halides, organic acid salts, acetylacetonates, inorganic acid salts, oxides, carbonyl compounds and amine compounds of these metals. Examples of suitable Group VIII metal compounds are, for example, Ru 3 (CO) 12 , Ru(NO 3 ) 2 , RuCl 3 (Ph 3 P) 3 , Ru(acac) 3 , Ir 4 (CO) 12 , IrSO 4 , RhCl 3 , Rh(NO 3 ) 3 , Rh(OAc) 3 , Rh 2 O 3 , Rh(acac)(CO) 2 , [Rh(OAc)(COD)] 2 , Rh 4 (CO) 12 , Rh 6 (CO) 16 , RhH(CO)(Ph 3 P) 3 , [Rh(OAc)(CO) 2 ] 2 , and [RhCl(COD)] 2 (wherein “acac” is an acetylacetonate group; “OAc” is an acetyl group; “COD” is 1,5-cyclooctadiene; and “Ph” is a phenyl group). However, it should be noted that the Group VIII metal compounds are not necessarily limited to the above listed compounds. The Group VIII metal is preferably rhodium. Rhodium compounds that contain ligands that can be displaced by the multidentate phosphites are a preferred source of rhodium. Examples of such preferred rhodium compounds are Rh(CO) 2 (acetylacetonate), Rh(CO) 2 (tC 4 H 9 COCHCO-tC 4 H 9 ), Rh 2 O 3 , Rh 4 (CO) 12 , Rh 6 (CO) 16 , Rh(O 2 CCH 3 ) 2 , and Rh(2-ethylhexanoate). Rhodium supported on carbon may also be used in this respect.; i.e., as the source of rhodium.

The present invention also provides a process for hydroformylation, comprising reacting an ethylenically unsaturated compound with a source of CO and H 2 in the presence of a catalyst precursor composition comprising a transition metal selected from the group of Co, Rh, Ru, Ir, Pd, and Pt, and at least one bidentate phosphonite ligand selected from the group represented by Formula I as described above.

The olefinically unsaturated starting materials useful in this invention include unsaturated organic compounds containing at least one carbon to carbon double bond, “C═C”, and preferably from 2 to 20 carbon atoms. Examples of suitable olefinically unsaturated organic compounds are linear terminal olefinic hydrocarbons, for example, ethylene, propylene, 1-butene, 1-pentene, and higher hydrocarbons; branched terminal olefins, for example isobutene and 2-methyl-1-butene; linear internal olefinic hydrocarbons, for example, cis- and trans-2-butene, cis- and trans-2-hexene, and cis- and trans-3-hexene; branched internal olefinic hydrocarbons, for example, 2,3-dimethyl-2-butene, 2-methyl-2-butene and 2-methyl-2-pentene; terminal olefinic hydrocarbon-internal olefinic hydrocarbon mixtures; for example, octenes prepared by dimerization of butenes; olefin oligomer isomer mixture from butadiene, dimer to tetramer of lower butadiene olefins including propylene, n-butene, isobutene or the like; and cycloaliphatic olefinic hydrocarbons, for example, cyclopentene, cyclohexene, 1-methylcyclohexene, cyclooctene, and limonene. The olefinically unsaturated compounds can be substituted with one or more functional groups containing a heteroatom, such as oxygen, sulfur, nitrogen, or phosphorus. Examples of these heteroatom-substituted olefinically unsaturated organic compounds include vinyl methyl ether, methyl oleate, oleyl alcohol, allyl alcohol, methyl 2-pentenoate, methyl 3-pentenoate, methyl 4-pentenoate, 3-pentenoic acid, 4-pentenoic acid, 3-pentenenitrile, 4-pentenenitrile, 7-octen-1-al, acrylonitrile, acrylic acid esters, methyl acrylate, methacrylic acid esters, methyl methacrylate, acrolein and other substituted olefinically unsaturated compounds. Other examples of suitable olefinic compounds include those substituted with an unsaturated hydrocarbon group including olefinic compounds containing an aromatic substituent such as styrene, α-methylstyrene, and allyl benzene; and diene compounds such as 1,3-butadiene, 1,5-hexadiene, 1,7-octadiene, and norbornadiene.

The invention is especially directed to hydroformylation processes in which a linear olefinically unsaturated aldehyde is prepared starting from a conjugated diene. The hydroformylation of C 4 to C 20 conjugated dienes to alkenals is especially preferred, for example, the hydroformylation of butadiene to pentenal.

It is a significant advantage of the invention that concentration of the olefinically unsaturated starting materials in the reactor may be increased. The normal undesirable side effects of such an increase, for example, the formation of oligomer and/or the inhibition of the catalyst, are avoided. Solvent recycle may be reduced or eliminated with its attendant benefits. Thus, in a preferred embodiment of the invention, the olefinically unsaturated starting material (i.e., the reactant involved in the hydroformylation reaction) is advantageously present in the liquid phase reaction media at a concentration of at least 40 weight percent.

The hydroformylation process according to the invention can be performed as described below:

The reaction conditions of the hydroformylation process according to this invention are in general the same as used in a conventional process, described, for example, in U.S. Pat. No. 4,769,498, which is incorporated herein by reference, and will be dependent on the particular starting ethylenically unsaturated organic compound. For example, the temperature can be from room temperature to 200° C., preferably from 50 to 120° C. The pressure may vary from atmospheric pressure to 20 MPa, preferably from 3 to 20 MPa for conjugated dienes such as 1,3-butadiene. The pressure is preferably equal to the combined hydrogen and carbon monoxide partial pressures. Extra inert gases may however be present. The molar ratio of hydrogen to carbon monoxide is generally between 10 to 1 and 1 to 10, preferably between 6 to 1 and most preferably 1 to 2.

The amount of Group VIII metal compound is not specially limited, but is optionally selected so that favorable results can be obtained with respect to catalyst activity and economy. In general, the concentration of Group VIII metal in the reaction media is between 10 and 10,000 ppm and more preferably between 50-500 ppm, calculated as the free metal.

The molar ratio of multidentate phosphorus ligand to Group VIII metal is not specially limited, but is optionally selected so that favorable results can be obtained with respect to catalyst activity, aldehyde selectivity, and process economy. This ratio generally is from about 0.5 to 100 and preferably from 1 to 5 (moles of ligand to moles of metal). Most preferably, the molar ratio of bidentate phosphonite ligand of Formula I to rhodium metal is selected to be equal to or slightly greater than the stoichiometric equivalent of one mole of ligand to one mole of metal.

The hydroformylation reaction of the instant invention can be performed in the presence of a solvent. The choice of solvent is not critical provided the solvent is not detrimental to catalyst, reactant and product. The solvent may be a mixture of reactants, such as the starting unsaturated compound, the aldehyde product and/or by-products. Suitable solvents include saturated hydrocarbons such as kerosene, mineral oil or cyclohexane, ethers such as diphenyl ether, tetrahydrofuran or a polyglycol, ketones such as methyl ethyl ketone and cyclohexanone, nitriles such as acetonitrile, valeronitrile, and benzonitrile, aromatics such as toluene, benzene and xylene, esters such as dimethylformamide, and sulfones such as tetramethylenesulfone.

The following examples are presented to more fully demonstrate and further illustrate various individual aspects and features of the present invention and the showings are intended to further illustrate the differences and advantages of the present invention. As such, the examples are felt to be non-limiting and are meant to illustrate the invention but are not meant to be unduly limiting.